Method and apparatus for fastening steel framing members using helical features

ABSTRACT

Various improved methods are provided for fastening two of more steel framing members together with a fastener. In one aspect, the fastening technique employs a fastener having a tip section such that a portion of the tip section extending beyond the underside of the framing members may be outwardly flared, thereby inhibiting removal of the fastener from the framing members In another aspect, the fastening technique employs a fastener having a steel tip nose for piercing the framing members and a plastic stem section, such that a portion of the stem section extending beyond the underside of the framing members expands, thereby inhibiting removal of the fastener from the framing members. In yet another aspect, the fastening technique employs a fastener having a coil section with an elastic characteristic.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Nos.60/299,994, 60/299,929, and 60/299,951 each of which were filed on Jun.21, 2001.

BACKGROUND OF THE INVENTION

The present invention relates generally to steel framing and, moreparticularly, to an improved cost-effective method for fastening steelframing.

Steel framing is revolutionizing the construction industry. Steel is ahigh quality framing material that will not shrink, warp, or attracttermites and other wood boring insects. In recent years, the price ofsteel has become more competitive with wood and other constructionmaterials. However, despite its advantages, steel framing has not becomeprevalent in the residential construction industry. The lack of a quickand cost effective technique for fastening steel members has preventedsteel framing from emerging as the predominant building material inresidential construction.

Therefore, it is desirable to provide a quick and cost-effectivetechnique for fastening steel members. It is envisioned that the steelfastening technique will be comparable in speed to an air nailer used tofasten wood materials. It is further envisioned that the steel fasteningtechnique will provide a minimal gap between steel members, a pulloutforce of at least 216 lb., a shear force of at least 164 lb., as well ascause minimal destruction of any galvanize coating on the steel members.

SUMMARY OF THE INVENTION

In accordance with the present invention, various improved methods areprovided for fastening two of more steel framing members together with afastener. In one aspect of the invention, the fastening techniqueemploys a fastener having a tip section such that a portion of the tipsection extending beyond the underside of the framing members may beoutwardly flared, thereby inhibiting removal of the fastener from theframing members In another aspect of the present invention, thefastening technique employs a fastener having a steel tip nose forpiercing the framing members and a plastic stem section, such that aportion of the stem section extending beyond the underside of theframing members expands, thereby inhibiting removal of the fastener fromthe framing members. In yet another aspect of the present invention, thefastening technique employs a fastener having a coil section with anelastic characteristic.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary prospective view of a steel framing memberhaving two additional steel framing members fastened thereto inaccordance with the present invention;

FIG. 2 is a side view of a first preferred embodiment of an outwardlyexpanding fastener in accordance with the present invention;

FIG. 3 is a bottom view of the outwardly expanding fastener illustratingfracture lines in accordance with the present invention;

FIG. 4 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the outwardly expanding fastener penetrating partiallythrough the steel members in accordance with the present invention;

FIG. 5 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the outwardly expanding fastener being driven against theouter surface of the steel members in accordance with the presentinvention;

FIG. 6 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating a pin being driven into a bottom portion of the outwardlyexpanding fastener in accordance with the present invention;

FIG. 7 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the radially outwardly flaring of the tip section of thefastener in accordance with the present invention;

FIG. 8 is a side view of a second preferred embodiment of an outwardlyexpanding fastener in accordance with the present invention;

FIG. 9 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the radially outwardly flaring of the tip section of thefastener in accordance with the present invention;

FIG. 10 is a side view of a third preferred embodiment of an outwardlyexpanding fastener in accordance with the present invention;

FIG. 11 is a bottom view of the third preferred embodiment of theoutwardly expanding fastener in accordance with the present invention;

FIG. 12 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the outwardly expanding fastener penetrating partiallythrough the steel members in accordance with the present invention;

FIG. 13 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the outwardly expanding fastener being driven against theouter surface of the steel members in accordance with the presentinvention;

FIG. 14 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the radially outwardly flaring of the tip section of thefastener in accordance with the present invention;

FIG. 15 is a side view of an exemplary steel tip fastener in accordancewith another aspect of the present invention;

FIGS. 16 and 17 are cross-sectional views, taken along line 5-5 of FIG.15, illustrating the steel tip fastener partially penetrating throughthe steel members in accordance with the present invention;

FIG. 18 is a cross-sectional view, taken along line 5-5 of FIG. 15,illustrating an enlarged stem portion of the steel tip fastener engagingthe underside of the steel member in accordance with the presentinvention;

FIG. 19 is a top view of an exemplary twisted spring fastener inaccordance with another aspect of the present invention;

FIG. 20 is a side view of the twisted spring fastener in accordance withthe present invention;

FIGS. 21 and 22 are cross-sectional views, taken along line 44 of FIG.19, illustrating the twisted spring fastener being screwed through twosteel members in accordance with the present invention;

FIG. 23 is a side view of a forth preferred embodiment of an outwardlyexpanding fastener in accordance with the present invention;

FIG. 24 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the outwardly expanding fastener being driven against theouter surface of the steel members in accordance with the presentinvention; and

FIG. 25 is a cross-sectional view, taken along line 5-5 of FIG. 1,illustrating the radially outwardly flaring of the tip section of thefastener in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a fragmentary prospective view of a longitudinalsteel framing member 12 having two upright steel framing members 14 and16 fastened thereto. Each c-shaped framing member includes a bottom walland two side walls having a thickness in the range from 0.018″ to0.071″. Additionally, each steel member may range from 33 ksi to 80 ksias is well known in the art. As will be more fully described below, oneor more fasteners 20 may be used to join the upright steel framingmembers 14 and 16 to the longitudinal steel framing member 12. While thefollowing description is provided with reference to this particularconfiguration, it is readily understood that the fastening technique ofthe present invention is applicable to any two or more adjacent membersmade of steel (e.g., carbon steel, hardened steel, stainless steel, toolsteel, etc.) or other material having similar attributes to those ofsteel (e.g., nonferrous metals, including nickel, alloys, titanium,copper and aluminum).

In accordance with one aspect of the present invention, one or moreoutwardly expanding fasteners 20 may be used to join the steel members.A first exemplary embodiment of an outwardly expanding fastener 20 isdepicted in FIG. 2. The fastener 20 is comprised of an integrally formedmember having a head section 22, a stem section 24 and a tip section 26.The fastener 20 further includes a bore 28 which is formed into the headsection 22 of the fastener. The bore 28 extends downwardly through thestem section 24 and into the tip section 26 of the fastener. As furtherdescribed below, the bore 28 is adapted to receive a pin 30 therein. Thefastener 20 is preferably comprised of a harden steel material or,alternatively, a softer steel material having a tip section formed of ahardened material such as carbide, ceramic, or a harden steel.

In operation, a two-step process is used to set the fastener 20 into theframing members. First, the expanding fastener 20 is driven into thesteel members until the head of the fastener seats against the outersurface of the steel members as shown in FIGS. 4 and 5. It is readilyunderstood that the driving device is configured to engage the headsection 22 of the fastener and may provide a backplate to preventunwanted deformation of the steel at the point at which the fastenerpierces the steel members. In one embodiment, the driving device drivesthe fasteners at relatively high speeds (e.g., greater than 50 feet persecond). In an alternative embodiment, the driving device may drive thefastener at lower speeds, but apply a relatively high force. One skilledin the art will readily recognize that an air nailer or other knowndriving devices may be configured to drive the fasteners 20 of thepresent invention into the steel members.

Once the fastener 20 has been driven into place, a pin 30 is then driventhrough the bore 28 and into contact with the inner surface of the tipsection 26 of the fastener. Upon impact, the pin 30 forces a portion ofthe fastener extending beyond the underside of the steel members toproject radially outward as shown in FIGS. 6 and 7. The radially flaredportions of the tip section 26 prevents removal of the fastener from thesteel members. To facilitate the separation of the tip section 26, it isenvisioned that one or more fracture lines 32 may be formed in the tipsection 26 of the fastener 20 as depicted in FIG. 3. It is furtherenvisioned that the fracture lines may not extend to the distal end ofthe tip section 26, thereby maintaining the structural integrity of thetip section 26′ as it is driven into the framing members. Alternatively,separation of tip section 26 can be facilitated by forming the tipsection 26 from two or more segmented members. The segmented members arenot connected to one another at tip section 26 and, therefore, do notrequire fracture lines 32 to facilitate the separation of tip section26.

In one embodiment, the pin 30 resides in the bore 28 of the fastener asshown in FIG. 2. In this case, the driving device may be configured toprovide a two-step actuation mechanism: a first step for driving thefastener into the steel members, and a second step for driving the pin30 into the bore of the fastener. In an alternative embodiment, it isenvisioned that the pin 30 may be integrated into the driving devicethat drives the fastener 20 into the steel members.

A second exemplary embodiment of the expanding fastener 20′ is depictedin FIG. 8. As described above, the expanding fastener 20 is comprised ofan integrally formed member having a head section 22′, a stem section24′, and a tip section 26′. However, in this embodiment, the tip section26′ of the fastener 20′ is designed to project radially outward into abutterfly position as shown in FIG. 9; otherwise the expanding fastener20′ is set using the two step process described above.

A third exemplary embodiment of the expanding fastener 20″ is depictedin FIG. 10. Likewise, the expanding fastener 20″ is primarily comprisedof an integrally formed member having a head section 22″, a stem section24″ and a tip section 26″. However, an annular groove 32″ may be formedalong the outer surface of the stem section 24″. As further describedbelow, the annular groove 32″ of the fastener 20″ is designed to curlthe inner surface of the hole made in the steel members. In addition,the fastener 20″ may be configured with different fracture lines asshown in FIG. 11, or alternatively, configured with two or moresegmented members.

Referring to FIGS. 12-14, the fastener 20″ is again driven into thesteel members until the head section 22″ of the fastener seats againstthe outer surface of the steel members as shown in FIG. 13. As thefastener passes through the steel members, the annular groove 32″ crimpstogether the portion of the steel members extending below the undersideof the steel members, thereby preventing separation of the two steelmembers. Once the fastener 20″ has been driven into place, a pin 30″ isthen driven into the bore 28″ of the fastener, thereby radiallyexpanding the tip section 26″ of the fastener as described above.

In another aspect of the present invention, one or more steel tipfasteners 40 may be used to join the steel members. An exemplary steeltip fastener 40 is shown FIG. 15. The steel tip fastener 40 is primarilycomprised of an integrally formed member having a head section 42 and astem section 44. The member is preferably formed of a plastic material.In addition, the fastener 40 further includes a piercing nose 46 formedat the tip of the fastener, such that the steel nose 42 has a radialdimension slightly less than the radial dimension of the stem section 44of the fastener 40. The piercing nose 46 is preferably formed of steelor other materials having similar attributes to those of steel.

When the steel tip fastener 40 is driven into the steel members, thepiercing nose 46 punches a hole clean through the steel members as shownin FIGS. 16 and 17. The plastic stem portion of the fastener then pressfits into the hole as shown in FIG. 18. Once the fastener has beendriven into place, a portion of the plastic stem will extend past theunderside of the steel members. It is envisioned that the friction ofthe plastic being forced though the hole at a high velocity will causethe portion of the stem extending past the underside of the steelmembers to expand as shown at 48 of FIG. 18. In this way, the expandedplastic portion will prevent removal of the fastener from the steelmembers.

In another aspect of the present invention, one or more twisted springfasteners 60 may be used to join the steel members. An exemplary springfastener 60 is depicted in FIGS. 19 and 20. The spring fastener 60 iscomprised of an integrally formed member having a head section 62 and acoil section 64. The fastener is preferably comprised of a steelmaterial, but may be comprised of other materials having an elasticcharacteristic, such as some plastic materials reinforced with glass,kevlar or graphite fibers.

A two-step process may be used to set the fastener 60. First, a pilothole is drilled or punched into the steel members. Second, the springfastener 60 is screwed into the pre-drilled hole until the steel membersare secured together as shown in FIGS. 21 and 22. It is envisioned thatthe head section 62 of the spring fastener 60 is adapted to receive oneor more types of torque transmitting devices. One skilled in the artwill readily recognize that various well known torque transmittingdevices (such as a drill) may be used to apply the appropriaterotational torque and downward force to drive the fastener 60 into thesteel members.

A forth exemplary embodiment of the expanding fastener 20′″ is depictedin FIG. 23. Likewise, the expanding fastener 20′″ is primarily comprisedof an integrally formed member having a head section 22′″, a stemsection 24′″ and a tip section 26′″. However, teeth 35′″ may extendalong the outer surface of the stem section 24′″. As further describedbelow, the teeth 35′″ of the fastener 20′″ are designed to engage withan outer surface of the steel members to further inhibit removal ofexpanding fastener 20′″. In addition, the fastener 20′″ may beconfigured with different fracture lines or alternatively, configuredwith two or more segmented members.

Referring to FIGS. 23-24, the fastener 20′″ is again driven into thesteel members until the head section 22′″ of the fastener seats againstthe outer surface of the steel members as shown in FIG. 24. Once thefastener 20′″ has been driven into place, a pin 30′″ is then driven intothe bore 28′″ of the fastener, thereby radially expanding the tipsection 26′″ of the fastener as described above. The teeth 35′″ engagewith the outer surface of the framing members, thereby furtherinhibiting removal of the fastener 20′″.

While the invention has been described in its presently preferred form,it will be understood that the invention is capable of modificationwithout departing from the spirit of the invention as set forth herein.

1-8. (canceled)
 9. A method of fastening two or more steel framingmembers together with a spring shaped fastener, comprising: (a)providing a spring-shaped fastener having a head section and a coilsection, where the coil section exhibits an elastic characteristic; (b)forming a hole through said framing members; (c) positioning thefastener adjacent to the hole and rotating the fastener about an axialaxis that substantially aligns with a center of the hole formed in theframing members; and (d) applying an axial force to the rotatingfastener, such that at least a portion of the coil section of thefastener passes entirely through the hole formed in the framing members.10. The method of claim 9, wherein (a) includes providing a fastenerhaving a coil section with a plurality of axially spaced apart coils.11. The method of claim 9, wherein the coil section includes a pluralityof coils and (d) includes passing at least one of the coils through thehole formed in the framing members.
 12. The method of claim 9, wherein(a) includes providing a steel fastener.
 13. The method of claim 9,wherein (a) includes providing a reinforced plastic fastener.
 14. Themethod of claim 9, wherein (d) includes maintaining the head section ofthe fastener on an opposite side of the framing members than the portionof the coil section of the fastener that passes entirely through thehole.
 15. The method of claim 9, further comprising elasticallydeforming the coil section while applying the axial force.
 16. Themethod of claim 9, wherein (b) includes punching the hole through theframing members.
 17. The method of claim 9, wherein (b) includesdrilling the hole through the framing members.
 18. A fastener forfastening two or more steel framing members together, the fastenercomprising: a head section operable to receive an axial and rotationalforce; and a coil section having an elastic characteristic, the coilsection operable to be rotated through an opening in adjacent framingmembers and elastically deformed therein, a portion of the coil sectionoperable to pass entirely through the opening and engage with a surfaceof the framing members and retain the framing members together betweenthe head section and the portion of the coil section that passedentirely through the opening.
 19. The fastener of claim 18, wherein thehead section includes an axially extending member.
 20. The fastener ofclaim 19, wherein the head section includes a pair of axially extendingmembers.
 21. The fastener of claim 18, wherein the coil section includesa plurality of spaced apart coils and the portion of the coil sectionoperable to pass entirely through the opening is at least one of thecoils.
 22. The fastener of claim 18, wherein the coil section includes aplurality of spaced apart coils that are elastically deformed in theopening.
 23. The fastener of claim 18, wherein the head section and coilsection are steel.
 24. The fastener of claim 18, wherein the headsection and the coil section are reinforced plastic.
 25. The fastener ofclaim 18, wherein the coil section includes a plurality of spaced apartcoils and different ones of the coils are disposed on and engaged withopposites sides of the opening and retain the framing members togethertherebetween.
 26. The fastener of claim 18, wherein the coil section isa helically wound section.
 27. The fastener of claim 18, wherein thehead section and the coil section are a single integral member.
 28. Afastener for fastening two or more steel framing members together, thefastener comprising: a head section having an axially extending memberand operable to receive an axial and rotational force; and a helicalcoil section having an elastic characteristic, the coil sectionincluding a plurality of spaced apart coils, the coil section operableto be rotated and axially pushed through an opening in adjacent framingmembers and elastically deformed therein, at least one of the coilsoperable to pass entirely through the opening and engage with a surfaceof the framing members and retain the framing members together betweenthe head section and the at least one coil that passed entirely throughthe opening.